Battery Module Bus Bar Welding Without Electrode Lead Bending

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Solution Overview

Problem

Conventional methods for producing battery modules require bending electrode leads to couple them with bus bars, leading to poor adhesion, weldability issues, and manual labor, which decreases automation efficiency.

Innovation Solution

A method involving a welding jig to press and weld electrode leads directly onto bus bars without bending, using inclined or horizontal portions on the bus bars for secure contact and improved alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrode leads are bent to contact the bus bar surface, then electrical coupling is achieved, but adhesion is poor and manual work is required

Engineering Contradiction:

Improveadhesion between electrode leads and bus barVSAvoidmanual work for bending electrode leads

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The bus bar is designed with an inclined portion that automatically guides the electrode lead into proper contact position during the welding process, eliminating the need for preliminary manual bending of the electrode lead

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of bending the electrode lead to match the bus bar surface, the bus bar is designed with an inclined portion that matches the natural state of the electrode lead, reversing the traditional approach

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If multiple electrode leads are overlapped at one point on the bus bar, then electrical coupling is achieved, but weldability deteriorates

Engineering Contradiction:

Improveelectrical couplingVSAvoidweldability

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The bus bar is divided into multiple inclined portions along its length, allowing each electrode lead to be coupled at a separate location rather than overlapping at a single point, thereby improving weldability

Inventive Principle:

Principle #1Segmentation

3Reliability

If electrode leads are bent to contact the bus bar, then electrical coupling is achieved, but elastic recovery force prevents close adhesion

Engineering Contradiction:

Improveelectrical couplingVSAvoidadhesion strength between electrode leads and bus bar

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The inclined portion of the bus bar is designed to automatically position the electrode lead in the correct contact orientation during welding, eliminating the need for bending and the subsequent elastic recovery that would compromise adhesion strength

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach ensures close adhesion and improved weldability between electrode leads and bus bars, eliminating manual bending and reducing overlap, thereby enhancing production line automation.

Implementation Method 1

by a welding jig, pressing the electrode leads so that the electrode leads come into contact with the bus bars, respectively

Methodology Applied

Scientific EffectMechanical Force: Force

Implementation Method 2

welding the electrode leads and the bus bars through an opening formed in the welding jig

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20240178530A1Method for producing battery module

Publication Date: 2024.05.30 LG ENERGY SOLUTION LTD

AI summary

A method for producing a battery module is provided. The method for producing a battery module includes: stacking a plurality of battery cells; disposing a plurality of bus bars adjacent to electrode leads respectively provided at the plurality of battery cells; by a welding jig, pressing the electrode leads so that the electrode leads come into contact with the bus bars, respectively; and welding the electrode leads and the bus bars through an opening formed in the welding jig.